U.S. patent application number 14/433884 was filed with the patent office on 2015-10-08 for multi-layer articles.
The applicant listed for this patent is 3M INNOVATIVE PROPERTIES COMPANY. Invention is credited to Amy S. Determan, Jeffrey O. Emslander, Korey W. Karls, Matthew T. Scholz.
Application Number | 20150283285 14/433884 |
Document ID | / |
Family ID | 49448340 |
Filed Date | 2015-10-08 |
United States Patent
Application |
20150283285 |
Kind Code |
A1 |
Karls; Korey W. ; et
al. |
October 8, 2015 |
MULTI-LAYER ARTICLES
Abstract
Multilayer articles having an absorbent nonwoven layer and a
barrier layer are described, including those having a
surfactant-treated, aliphatic polyester, nonwoven absorbent layer
and a barrier layer. Multilayer articles including a tie layer used
to enhance the bond between the hydrophilic absorbent layer and the
barrier layer are also described. Methods of making and using such
articles are also described.
Inventors: |
Karls; Korey W.; (Coon
Rapids, MN) ; Scholz; Matthew T.; (Woodbury, MN)
; Emslander; Jeffrey O.; (Stillwater, MN) ;
Determan; Amy S.; (Mahtomedi, MN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
3M INNOVATIVE PROPERTIES COMPANY |
Saint Paul |
MN |
US |
|
|
Family ID: |
49448340 |
Appl. No.: |
14/433884 |
Filed: |
October 11, 2013 |
PCT Filed: |
October 11, 2013 |
PCT NO: |
PCT/US2013/064481 |
371 Date: |
April 7, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61713107 |
Oct 12, 2012 |
|
|
|
Current U.S.
Class: |
442/392 ;
442/398 |
Current CPC
Class: |
A61F 13/0206 20130101;
Y10T 442/671 20150401; B32B 27/08 20130101; B32B 27/12 20130101;
B32B 2307/7265 20130101; B32B 2262/0276 20130101; Y10T 442/678
20150401; A61F 13/022 20130101; A61L 15/48 20130101; A61L 31/14
20130101; A61L 15/42 20130101; D04H 1/435 20130101; B32B 5/24
20130101; A61L 15/24 20130101; B32B 5/022 20130101; B32B 2535/00
20130101 |
International
Class: |
A61L 15/24 20060101
A61L015/24; B32B 27/08 20060101 B32B027/08; B32B 27/12 20060101
B32B027/12; B32B 5/02 20060101 B32B005/02; B32B 5/24 20060101
B32B005/24 |
Claims
1. A multilayer article comprising a hydrophilic absorbent layer, a
polyolefin barrier layer, and a tie layer bonding the absorbent
layer to the barrier layer; wherein the absorbent layer comprises a
nonwoven web of fibers comprising an aliphatic polyester combined
with a surfactant.
2. The multilayer article of claim 1, wherein the tie layer
comprises a copolymer of at least one olefin monomer and at least
one polar monomer.
3. The multilayer article of claim 2, wherein the copolymer further
comprises at least one reactive monomer, wherein the reactive
monomer comprises a reactive group that covalently reacts with a
hydroxyl group.
4. The multilayer article of claim 2, wherein the tie layer further
comprises a reactive polymer comprising at least one reactive
monomer, wherein the reactive monomer comprises a reactive group
that covalently reacts with a hydroxyl group.
5. The multilayer article according to claim 2, wherein at least
one olefin monomer is ethylene.
6. The multilayer article according to claim 2, wherein at least
one polar monomer is selected from the group consisting of vinyl
acetate, a C1 to C8 acrylate, a C1 to C4 acrylic acid, and
combinations thereof.
7. The multilayer article according to claim 2, wherein the
reactive group of the reactive monomer is an anhydride group or an
epoxy group.
8. The multilayer article according to claim 1, wherein the tie
layer further comprises a tackifier.
9. The multilayer article according to claim 1, wherein the tie
layer further comprises a thermoplastic elastomer.
10. The multilayer article according to claim 9, wherein the
thermoplastic elastomer is a block copolymer comprising alkyl
methacrylate and alkyl acrylate blocks.
11. The multilayer article according to claim 10, wherein the
thermoplastic elastomer is a poly(methyl methacrylate)-poly(butyl
acrylate)-poly(methyl methacrylate) copolymer.
12. The multilayer article according to claim 1, wherein the tie
layer further comprises an alkyl benzoate plasticizer.
13. A multilayer article comprising an absorbent layer comprising a
hydrophilic first ply and a second ply, and a polyolefin barrier
layer bonded to the second ply; wherein the first ply comprises a
first nonwoven web of fibers comprising an aliphatic polyester
combined with a surfactant, the second ply comprises a second
nonwoven web of fibers comprising the aliphatic polyester.
14. The multilayer article of claim 13, wherein the barrier layer
is directly bonded to the second ply.
15. The multilayer article of claim 14, wherein the barrier layer
is indirectly bonded to the second ply; wherein the multilayer
article further comprises a tie layer positioned between and bonded
to the barrier layer and the second ply.
16. The multilayer article of claim 15, wherein the tie layer
comprises a copolymer of at least one olefin monomer and at least
one polar monomer.
17. The multilayer article of claim 16, wherein the copolymer
further comprises at least one reactive monomer, wherein the
reactive monomer comprises a reactive group that covalently reacts
with a hydroxyl group.
18. The multilayer article according to claim 16, wherein at least
one olefin monomer is ethylene.
19. The multilayer article according to claim 16, wherein at least
one polar monomer is selected from the group consisting of vinyl
acetate, a C1 to C8 acrylate, a C1 to C4 acrylic acid, and
combinations thereof.
20. The multilayer article according to claim 16, wherein the
reactive group of the reactive monomer is an anhydride group or an
epoxy group.
21-32. (canceled)
Description
FIELD
[0001] The present disclosure relates to multilayer articles having
an absorbent nonwoven layer and a polyolefin barrier layer. The
present disclosure also relates to multilayer articles including a
tie layer; specifically tie layers used to enhance the bond between
a hydrophilic absorbent layer and a polyolefin barrier layer.
Methods of making and using such articles are also described.
SUMMARY
[0002] Briefly, in one aspect, the present disclosure provides a
multilayer article comprising a hydrophilic absorbent layer, a
polyolefin barrier layer, and a tie layer bonding the absorbent
layer to the barrier layer. The absorbent layer comprises a
nonwoven web of fibers comprising an aliphatic polyester combined
with a surfactant.
[0003] In another aspect, the present disclosure provides a
multilayer article comprising an absorbent layer comprising a
hydrophilic first ply and a second ply, and a polyolefin barrier
layer bonded to the second ply. The first ply comprises a first
nonwoven web of fibers comprising an aliphatic polyester combined
with a surfactant and the second ply comprises a second nonwoven
web of fibers comprising the aliphatic polyester. In some
embodiments, the barrier layer is directly bonded to the second
ply. In some embodiments, the barrier layer is indirectly bonded to
the second ply; wherein the multilayer article further comprises a
tie layer positioned between and bonded to the barrier layer and
the second ply.
[0004] In some embodiments, the tie layer comprises a copolymer of
at least one olefin monomer and at least one polar monomer. In some
embodiments, the copolymer further comprises at least one reactive
monomer, wherein the reactive monomer comprises a reactive group
that covalently reacts with a hydroxyl group. In some embodiments,
the tie layer further comprises a reactive polymer comprising at
least one reactive monomer, wherein the reactive monomer comprises
a reactive group that covalently reacts with a hydroxyl group. In
some embodiments, the tie layer further comprises a tackifier.
[0005] In some embodiments, at least one olefin monomer is
ethylene. In some embodiments, at least one polar monomer is
selected from the group consisting of vinyl acetate, a C1 to C8
acrylate, a C1 to C4 acrylic acid, and combinations thereof. In
some embodiments, the reactive group of the reactive monomer is an
anhydride group or an epoxy group. In some embodiments, the tie
layer includes a thermoplastic elastomer. In some embodiments, the
thermoplastic elastomer is a block copolymer comprising alkyl
methacrylate and alkyl acrylate blocks, e.g., a poly(methyl
methacrylate)-poly(butyl acrylate)-poly(methyl methacrylate)
copolymer. In some embodiments, the tie layer further comprises an
alkyl benzoate plasticizer.
[0006] In some embodiments, the aliphatic polyester comprises
poly(lactic acid). In some embodiments, the surfactant comprises at
least one of an anionic surfactant and a nonionic polyethoxylated
surfactant. In some embodiments, the absorbent layer further
comprises a nonvolatile carrier blended with the aliphatic
polyester and the surfactant. In some embodiments, the nonvolatile
carrier comprises at least one of a polyalkylene glycol, a
thermally stable polyhydric alcohol, a low molecular weight ester
of a polyhydric alcohol and combinations thereof.
[0007] In some embodiments, the olefin comprises at least one of
polyethylene and polypropylene. In some embodiments, the
polyethylene comprises at least one of low density polyethylene and
linear low density polyethylene.
[0008] The above summary of the present disclosure is not intended
to describe each embodiment of the present invention. The details
of one or more embodiments of the invention are also set forth in
the description below. Other features, objects, and advantages of
the invention will be apparent from the description and from the
claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 illustrates an exemplary multilayer article according
to some embodiments of the present disclosure.
[0010] FIG. 2 illustrates another exemplary multilayer article
according to some embodiments of the present disclosure.
[0011] FIG. 3 illustrates yet another exemplary multilayer article
according to some embodiments of the present disclosure.
DETAILED DESCRIPTION
[0012] A patient's skin flora entering a surgical wound is
generally recognized as the primary cause of surgical site
infections. In an effort to inhibit or prevent flora present on a
patient's skin from entering the wound, sterile disposable drapes
are used to cover the patient during surgical procedures.
Preferably, absorbent drapes are used in an effort to prevent
fluids from draining into the wound, or onto operating personnel or
the floor. However, absorbent layers by themselves could provide a
fluid path for bacteria on the skin to pass through the drape and
into the wound. Thus, drapes are often multilayer articles that may
include a barrier layer to prevent skin bacteria flora from
migrating from the skin, through the drape, and into the wound.
[0013] Current drapes also satisfy other criteria such as being
strong (high machine and cross direction tensile strength), and
having low flammability, while remaining relatively low in cost.
There is a desire, however, to make a strong, fluid impervious,
absorbent drape that is softer and more drapable. There is also a
desire to increase the content of resource-renewable (i.e., plant
derived as opposed to petroleum derived) materials in the drape as
much as possible. There is a further desire to provide these and
other benefits while maintaining low cost, as drapes are generally
a single-use, disposable product.
[0014] Traditionally, thermoplastic polymers have been used to
create layers suitable for the absorbent and barrier layers such as
blown and cast films, extruded sheets, foams, fibers and products
made from fibers such as woven and knitted fabrics, and non-woven
fibrous webs. Traditionally, many of these layers have been made
from petroleum-based thermoplastics such as polyolefins. However,
there is a growing interest in replacing these petroleum-based
polymers with resource renewable polymers, i.e. polymers derived
from plant based materials. Ideal resource renewable polymers are
"carbon dioxide neutral" meaning that as much carbon dioxide is
consumed in growing the plant based material as is given off when
the product is made and disposed of. Biodegradable materials have
adequate properties to permit them to break down when exposed to
conditions which lead to composting. Examples of materials thought
to be biodegradable include aliphatic polyesters such as
poly(lactic acid), poly(glycolic acid), poly(caprolactone),
copolymers of lactide and glycolide, poly(ethylene succinate),
polybutylene succinate), polyhydroxybutyrate, and combinations
thereof.
[0015] In some embodiments, the absorbent layer of the present
disclosure comprises aliphatic polyesters and/or polyamides. In
some embodiments, the absorbent layer comprises fibers comprising
aliphatic polyesters and/or polyamides. In some embodiments, the
absorbent layer comprises a woven or nonwoven web. In some
embodiments, the nonwoven web may be a melt-blown, spun-bond,
spun-laced, and/or wet or dry laid.
[0016] Exemplary aliphatic thermoplastic polyesters include
poly(lactic acid), poly(glycolic acid), poly(lactic-co-glycolic
acid), polyhydroxybutyrate, polyhydroxyvalerate, blends, and
copolymers thereof. Blends of aliphatic thermoplastic polyesters
and blends of one or more aliphatic thermoplastic polyesters with
one or more of a variety of other polymers including aromatic
polyesters, aliphatic/aromatic copolyesters, cellulose esters,
cellulose ethers, thermoplastic starches, ethylene vinyl acetate,
polyvinyl alcohol, ethylenevinyl alcohol, and the like may also be
used. In blended compositions that include thermoplastic polymers
which are not aliphatic polyesters, the aliphatic polyester is
typically present at a concentration of greater than 60% by weight
of total blend, preferably at least 70%, e.g., at least 75, 80, 85,
90 and even at least 95% by weight of total blend.
[0017] These webs are generally not sufficiently water absorbent
unless combined with water absorbent fibers such as cellulose,
cellulose derivatives, and other polysaccharide based fibers and
the like. Alternatively, or in addition to such an approach, the
aliphatic polyester resin can be combined with one or more
surfactants. For example, in some embodiments, surfactants may be
sprayed, coated or otherwise applied to the surface of fibers
comprising an aliphatic polyester. Coating methods to provide a
hydrophilic surface are known, but also have some limitations.
First, the extra step required in coating preparation is expensive
and time consuming. Second, many of the solvents used for coating
are flammable liquids or have exposure limits that require special
production facilities. Third, the quantity of surfactant can also
be limited by the solubility of the surfactant in the coating
solvent and the thickness of the coating.
[0018] In some embodiments, aliphatic thermoplastic polyester(s)
and surfactant(s) are combined by blending them together to yield a
biocompatible, durable hydrophilic composition. In some cases the
surfactant may be dissolved in or along with a surfactant carrier.
The surfactant carrier and/or surfactant may be a plasticizer for
the thermoplastic aliphatic polyester. Such plasticized aliphatic
polyester compositions generally have a lower melt processing
temperature, can yield a more flexible output material, and may
have a lower glass transition temperature.
[0019] Such compositions can be processed to produce hydrophilic
layers and fibers suitable for creating woven and non-woven
hydrophilic layers. In some embodiments, the composition is
melt-processable, such that the composition is capable of being
extruded. In some embodiments, the composition is solvent soluble
or dispersible and the composition may be solvent cast or solvent
spun to form films, fibers, or foams. The melt processable
composition of aliphatic polyesters and surfactants exhibit durable
hydrophilicity, as do films, fibers, and webs produced from such
compositions.
[0020] The aliphatic polyester component of the composition of this
disclosure typically comprises at least 70 weight percent, in some
embodiments, at least 85 weight percent, and even at least 95
weight percent, based on the total weight of the aliphatic
polyesters and the surfactants.
[0021] As used herein the term "surfactant" means an amphiphile (a
molecule possessing both polar and nonpolar regions which are
covalently bound) capable of reducing the surface tension of water
and/or the interfacial tension between water and an immiscible
liquid. The term is meant to include soaps, detergents,
emulsifiers, surface active agents, and the like. In applications
in which biodegradability is important, it may be desirable to
incorporate biodegradable surfactants, which typically include
ester and/or amide groups that may be hydrolytically or
enzymatically cleaved. In certain embodiments, the surfactants
useful in the compositions of the present invention are anionic
surfactants selected from the group consisting of alkyl, alkenyl,
alkaryl and arakyl sulfonates, sulfates, phosphonates, phosphates
and mixtures thereof. Included in these classes are
alkylalkoxylated carboxylates, alkyl alkoxylated sulfates,
alkylalkoxylated sulfonates, and alkyl alkoxylated phosphates, and
mixtures thereof. Aralkyl and alkaryl sulfonates, sulfates,
phosphonates and phosphates also may be useful such as branched or
straight chain dodecylbenzene sulfonate, sodium salt. In some
embodiments, the alkoxylate is made using ethylene oxide and/or
propylene oxide with 0-100 moles of ethylene and propylene oxide
per mole of hydrophobe. In certain embodiments, the surfactants are
selected from the group consisting of sulfonates, sulfates,
phosphates, carboxylates and mixtures thereof. In some embodiments,
the surfactant is selected from (C8-C22) alkyl sulfate salts (e.g.,
sodium salt), di(C8-C13 alkyl)sulfosuccinate salts, C8-C22 alkyl
sarconsinate, C8-C22 alkyltaurates, C8-C22 alkyl lactylates and
combinations thereof.
[0022] Certain nonionic polyethoxylated surfactants are useful in
improving the absorption rate and/or absorption capacity. In some
embodiments, surfactant systems comprising a combination of an
anionic surfactant and a polyalkoxylated nonionic surfactant may be
used. Generally, the polyalkoxylated nonionic surfactant has at
least 50% mole % oxyethylene groups, and more preferably at least
75 mole % oxyethylene groups as a percentage of the polyalkoxylate
group. Preferably the nonionic surfactant is a liquid at room
temperature which is believed to facilitate migration to the
surface. Preferred nonionic surfactants have a branched alkyl
chain, an unsaturated alkyl chain, multiple polalkoxylate groups or
a combination thereof. Examples include alkyl ether polyalkoxylates
(e.g. Tergitol 15-S-7, an ethoxylated secondary alcohol available
from Dow Chemical Company, Midland Mich.), alkyl ester
polyalkoxylates (e.g. PEG 400 monolaurate, PEG 600 distearate),
alkyl amide polyalkoxylates (e.g. PEG 5 lauramide, PEG 6 lauric
diethanolamide), alkoxylated sorbitan fatty esters (e.g. PEG 20
sorbitan monolaurate, PEG 40 sorbitan dioleate, etc), alkoxylated
esters and ethers of polyhydric alcohols, and the like as well as
combinations thereof.
[0023] If used, the one or more surfactants may be incorporated at
a level suitable to produce the desired result. In some
embodiments, surfactant(s) are blended with aliphatic polyester(s)
and are present in a total amount of at least 0.5 wt. %, at least
0.75 wt. %, at least 1 wt. %, or at least 2 wt %, based on the
total weight of the blended composition. In certain embodiments, in
which a very hydrophilic web is desired, or a web that can
withstand multiple assaults with aqueous fluid, the surfactant
component comprises greater than 2 wt. %, greater than 3 wt. %, or
even greater than 5 wt. % of the blended composition. However, in
some embodiments, the surfactant(s) are present in a total amount
of no greater than 15 wt. %, no greater than 10 wt. %, no greater
than 5 wt. %, or even no greater than 3 wt. %, based on the total
weight of the aliphatic polyester web.
[0024] In some embodiments the webs are formed from multicomponent
fibers such as bicomponent fibers. In some embodiments it may be
desirable to use a sheath/core or side by side fiber construction
where the core or one side is essentially free of surfactant or has
reduced surfactant in order to improve the strength of the fiber
and web. In a particularly preferred embodiment the fibers are
spunbond fibers formed using a bicomponent sheath/core die where
the core is free of surfactant and the sheath has sufficient
surfactant to ensure the web is hydrophilic and absorbent.
Generally such constructions have at least 2 wt. % of the sheath
comprised of one or more surfactants. More preferably these
bicomponent fibers have at least 2.5 wt. % of the sheath comprised
of one or more surfactants.
[0025] In some embodiments, it may be convenient to use a
surfactant predissolved in a nonvolatile carrier. The carrier is
typically thermally stable and can resist chemical breakdown at
processing temperatures which may be as high as 150.degree. C.,
180.degree. C., 200.degree. C. or even 250.degree. C. In some
embodiments, the carrier is a liquid at 23.degree. C. Exemplary
carriers include polyalkylene glycols such as polyethylene glycol,
polypropylene glycol, random and block copolymers of ethylene oxide
and propylene oxide, thermally stable polyhydric alcohols such as
propylene glycol, glycerin, polyglycerin, and the like. Carriers
also may include low molecular weight esters of polyhydric alcohols
such as triacetin, glyceryl caprylate/caprate,
acetyltributylcitrate, and the like. We have found that these
carriers improve absorbent capacity and absorbent rate most likely
due to enhancing migration of the surfactant(s) to the surface. In
some embodiments the nonvolatile carrier is a pourable liquid at
23.degree. C. In certain embodiments, one or more of the
surfactants may be a liquid at 23.degree. C. and may function as
both a surfactant and a carrier for other surfactants that are
solids or pastes at 23.degree. C.
[0026] Since the carrier is substantially nonvolatile it will in
large part remain in the composition and may function as an organic
plasticizer. As used herein a plasticizer is a compound having a
molecular weight less than 10,000 daltons which when added to the
polymer composition results in a decrease in the glass transition
temperature.
[0027] In some embodiments, the absorbent layer comprises a
plurality of continuous fibers comprising one or more thermoplastic
aliphatic polyesters and a thermoplastic antishrinkage additive in
an amount greater than 0 wt. % and no more than 15 wt. % of the
fibers. In some embodiments, the fibers exhibit molecular
orientation. In some embodiments, the absorbent layer has at least
one dimension which decreases by no greater than 10% in the plane
of the layer when the layer is heated to a temperature above a
glass transition temperature of the fibers, but below the melting
point of the fibers. In some exemplary embodiments, the molecular
orientation of the fibers results in a bi-refringence value of at
least 0.01. In most embodiments, the fibers are microfibers, and
particularly fine fibers.
[0028] In some embodiments, the aliphatic polyester is
semicrystalline. In some embodiments, the thermoplastic
antishrinkage additive comprises at least one thermoplastic
semicrystalline polymer. In some embodiments, the thermoplastic
semicrystalline polymer selected from the group consisting of
polyethylene, linear low density polyethylene, polypropylene,
polyoxymethylene, poly(vinylidine fluoride), poly(methyl pentene),
poly(ethylene-chlorotrifluoroethylene), poly(vinyl fluoride),
poly(ethylene oxide), poly(ethylene terephthalate), poly(butylene
terephthalate), semicrystalline aliphatic polyesters including
polycaprolactone, aliphatic polyamides such as nylon 6 and nylon
66, and thermotropic liquid crystal polymers.
[0029] It was found that surface treatment and subsequent drying of
fabrics made from polymers having a glass transition temperature,
Tg, less than the drying temperature resulted in a significant
increase in stiffness, resulting in reduced softness and
drapeability. In contrast, adding the surfactant to the polymer
composition, e.g., as a melt additive preserves softness and
drapeability, and may reduce costs. Also, the addition of
surfactants and particularly surfactants in carriers to the
melt-processable compositions can reduce the tensile strength of
the resulting material significantly. This is believed to be due at
least in part to a plasticization of the polymer with resulting
decrease in crystallinity. Thus, the present inventors discovered
that it may be preferred to add the surfactant to the sheath of a
sheath/core bicomponent fiber. Keeping the core free of surfactant
and carrier can greatly improve the overall strength. Such an
approach may also accelerate migration of the surfactant to the
surface of the fiber. Generally, the core represents at least 40%
by volume (determined by relative cross-sectional area) of the
bicomponent fibers. In some embodiments, the fiber core is at least
50% by volume, e.g., at least 60% by volume and even at least 80%
by volume of the bicomponent fibers. A similar effect may be
achieved using a side by side fiber configuration where one side
comprises the surfactant composition and the other does not. In
some embodiments, the surfactant free side (or reduced surfactant)
is at least 50% by volume, e.g., at least 60% by volume and even at
least 80% by volume of the bicomponent fibers.
[0030] In some embodiments, the absorbent layer will exhibit a
basis weight, which may be varied depending upon the particular end
use of the web. Typically, the absorbent layer has a basis weight
of no greater than about 1000 grams per square meter (gsm). In some
embodiments, the absorbent layer has a basis weight of from about
1.0 gsm to about 500 gsm. In other embodiments, the absorbent layer
has a basis weight of from about 10 gsm to about 300 gsm. For use
in some applications such as medical fabrics, including surgical
drapes, surgical gowns and sterilization wraps, the basis weight is
typically from about 10 gsm to about 100 gsm, e.g., 15 gsm to about
60 gsm.
[0031] As with the basis weight, the absorbent layer will exhibit a
thickness, which may be varied depending upon the particular end
use of the web. Typically, absorbent layer has a thickness of no
greater than about 300 millimeters (mm) In some embodiments, the
absorbent layer has a thickness of from about 0.5 mm to about 150
mm when measured with essentially no pressure applied such as by
using an optical comparator. In other embodiments, the absorbent
layer has a thickness of from about 1.0 mm to about 50 mm. For use
in some applications such as medical fabrics, including surgical
drapes, surgical gowns and sterilization wraps, the thickness is
generally from about 0.1 mm to about 10 mm, e.g., 0.25 mm to about
2.5 mm.
[0032] In certain embodiments, the absorbent layer comprises at
least one nonwoven fibrous web, which can be prepared by
fiber-forming processes in which filaments of fiber-forming
material are formed by extrusion of a mixture of one or more
thermoplastic aliphatic polyesters with a surfactant additive
composition in an amount greater than 0.25% and no more than 10% by
weight of the mixture to which it is added (i.e. sheath, core,
entire fiber etc.), subjected to orienting forces, and passed
through a turbulent field of gaseous currents while at least some
of the extruded filaments are in a softened condition and reach
their freezing temperature (e.g., the temperature at which the
fiber-forming material of the filaments solidifies) while in the
turbulent field. The surfactant composition may comprise one or
more of the previously mentioned surfactants and optionally a
surfactant carrier. Such fiber forming processes include, for
example, melt-spinning (i.e. spunbond), filament extrusion,
electrospinning, gas jet fibrillation or combinations thereof.
[0033] In some embodiments, absorbent nonwoven fibrous webs can be
prepared by fiber-forming processes in which substantially
non-molecularly oriented filaments of fiber-forming material are
formed from a mixture of one or more thermoplastic aliphatic
polyesters with a surfactant additive in an amount greater than
0.25% and no more than 10% by weight of the mixture to which it is
added, before or during extrusion. In some exemplary embodiments,
the fibers may be formed using a melt-blowing (e.g. BMF) process.
In some exemplary embodiments, the fibers may be formed using a
spunbond process.
[0034] The multilayer articles of the present disclosure also
include a barrier layer. The barrier layer may comprise one or more
plies. As used herein the term "barrier layer" refers to a layer
that does not allow liquid water to pass through at a pressure of 5
kPa when tested by the Hydrohead method as described in I. S. EN
20811-1993 Textiles--Determination of Resistance to Water
Penetration-Hydrostatic Pressure Test. In some embodiments, barrier
layers exceed 7.5 kPa or even 10 kPa when tested by this method. In
some embodiments, barrier layers do not allow liquid water to pass
through when tested by the Hydrohead method as described in I. S.
EN 20811-1993 at 6 kPa per minute pressure increase with the
barrier side up and no other support.
[0035] In some embodiments, suitable barriers include nonporous
films. Generally, the barrier layers are polyolefin barrier layers.
As used herein, a "polyolefin barrier layer" is a barrier layer
wherein at least 60 wt. % of polymers or copolymers present in the
barrier layer comprise at least 50 wt. % olefin monomer units. In
some embodiments, at least 70 wt. % or even at least 80 wt. %
polymers or copolymers in the polyolefin barrier layer comprise at
least 50 wt. % olefin monomer units. In some embodiments, the
polymers and copolymers comprise at least 70 wt. %, e.g., at least
80 wt. %, or even at least 90 wt. % olefin monomer units. In some
embodiments, at least one polymer or copolymer consists of olefin
monomers. In some embodiments, at least 80 wt. %, in some
embodiments, at least 90 wt. %, or even at least 95 wt. % of the
polymers or copolymers present in the barrier layer consist of
olefin monomers. Exemplary materials suitable for use in the
barrier layer include polyolefins such as low density polyethylene
(LDPE), linear low density polyethylene (LLDPE), metallocene
polyethylene, polypropylene (PP), metallocene polypropylene, and
the like. Suitable polymers for the barrier layer also include
blends of polyethylenes, blends of polypropylenes, blends of
polyethylene and polypropylene, blend polyethylene and/or
polypropylene with suitable amorphous polymers, copolymers made
from ethylene and propylene monomers, and blends of such copolymers
with polyethylenes, polypropylenes, suitable amorphous polymers,
semi-crystalline/amorphous polymers, heterophasic polymers, or
combinations thereof. Other useful polymers that may be used in the
barrier layer include elastomeric thermoplastic polymers. Examples
of useful polymers that can be included in the barrier layer
include those available under the trade names EXXPOL, EXCEED, and
EXACT from Exxon Chemical Company of Baytown, Tex.; those available
under the trade names ENGAGE, ACHIEVE, ATTAIN, AFFINITY, and ELITE
from Dow Chemical Company of Midland, Mich.
[0036] In some embodiments, the absorbent layer may be bonded
directly to the barrier layer. Despite the individual advantages of
using a hydrophilic, surfactant-treated aliphatic polyester
absorbent layer and a polyolefin barrier layer, the present
inventors found that bonding these layers to each other to form the
desired finished multilayer article was difficult. It was
particularly difficult to bond these incompatible layers to each
other to produce an article that could withstand use in a humid,
moist, or wet environment. For example, while sterilization in high
humidity increases absorbency it can greatly decrease the adhesion
of the barrier film to the nonwoven when tested by a hydrohead
method. In addition, the present inventors discovered that,
contrary to conventional wisdom, corona treatment of the absorbent
layer decreased the hydrohead adhesion values.
[0037] Absorbent layers are generally polar and hydrophilic, while
barrier layers are typically nonpolar and hydrophobic. As a result,
hydrophilic absorbent layers are generally incompatible with and
bond poorly to common barrier layers, particularly polyolefin-based
film barriers.
[0038] The present inventors have surprisingly discovered a variety
of approaches to overcome one or more of these and other
difficulties, while delivering one or more of the desired advances
in drapes. In one approach, a tie layer having a high content of
polar monomer is used to bond the absorbent layer to the barrier
layer. In another approach, a multiply absorbent layer is used with
one ply having little or no surfactant and a second ply containing
sufficient surfactant to make the absorbent layer immediately and
rapidly absorbent. The low-surfactant content first ply is
positioned between and bonds together the barrier layer and the
high-surfactant content second layer. In some embodiments,
combinations of these methods may be used.
[0039] Referring to FIG. 1, in some embodiments, absorbent layer
110 of multilayer article 100 is indirectly bonded to barrier layer
130 using tie-layer 120. Although shown as a single layer, in some
embodiments, two-or more intermediate layers may be used. In one
aspect of this disclosure, the present inventors have discovered
certain tie-layers suitable for bonding absorbent layers to barrier
layers. For example, the present inventors have discovered that a
tie layer having high polar monomer content and, optionally, a
reactive group capable of covalently reacting with a hydroxyl group
can improve the bond between incompatible absorbent and barrier
layers.
[0040] In some embodiments, the tie layer comprises a copolymer of
polyolefin monomer(s) with a polar monomer. Exemplary polar
monomers include vinyl acetate (VA); C1-C8 acrylates such as ethyl
acrylate (EA), methyl acrylate (MA), butyl acrylate (BA), and
2-ethylhexyl acrylate; and C1-C4 acrylic acids (e.g., acrylic acid
and methacrylic acid). In some embodiments, the copolymer of the
tie layer comprises a high content of the polar monomer(s). For
example, when the tie layer comprises an ethylene vinyl acetate
copolymer (EVA), the vinyl acetate content may be greater than 30%,
35%, and even greater than 40% by weight of the copolymer. Other
exemplary tie layer include copolymers of ethylene and C1-C8
acrylates such as ethylene ethyl acrylate (EEA), ethylene methyl
acrylate (EMA), ethylene butyl acrylate (EBA), and 2 ethylhexyl
acrylate. In some embodiments, the copolymers have relatively high
acrylate content by weight. In some embodiments, the acrylate is
present at greater than 15%, 17%, and preferably 20% by weight in
the copolymer. In some embodiments, the copolymers have relatively
high acrylic acid content, e.g., copolymers of ethylene and C1-C4
acrylic acids (e.g., EAA). In some embodiments, the acrylic acid
content is greater than 7 wt. %, or even greater than 9 wt. %
acrylic acid. Exemplary copolymers include EVA copolymers available
from LANXESS GMBH under the trade name LAVAMELT, e.g., LAVAMELT
450, and methyl acrylate ethylene copolymers (EMA) such as those
available under the trade name ELVALOY from Dupont, such as ELVALOY
AC 12024.
[0041] In some embodiments, the tie layer also comprises one or
more polymers comprising a reactive group. In some embodiments, the
reactive group is capable of covalently bonding to a hydroxyl group
such as the terminal groups on an aliphatic polyester. Examples of
such polymers include those comprising anhydride groups or epoxy
groups. In some embodiments, the tie layer is a copolymer
comprising at least three different monomers: an olefin monomer
(e.g., ethylene), a polar nonreactive monomer (e.g., vinyl acetate
or a methacrylate monomer) and a reactive monomer (e.g., a monomer
having an anhydride or epoxy group). In some embodiments, the
copolymer of the tie layer comprises greater than 0.5, e.g.,
greater 1, greater than 3, or even greater than 5 wt. % reactive
monomer and greater than 10, greater than 15, or even greater than
18 wt. % nonreactive polar monomer. Exemplary reactive tie layer
copolymers include those available under the trade name TYMAX from
Westlake Chemical Corp., Houston Tex. (e.g., TYMAX GA7001 which is
believed to be a terpolymer of 20% methyl acrylate, ethylene, and
an anhydride containing reactive monomer) and those available under
the trade name LOTADUR from Arkema (e.g., LOTADUR AX8900 which is
believed to be a terpolymer of 24% methylacrylate, 8%
glycidylmethyacrylate and 68% ethylene.
[0042] In some embodiments, the tie layer may include one or more
plasticizers. Exemplary plasticizers include alkyl benzoates such
as those available under the trade name FINSOLVE from Innospec
Performance Chemicals.
[0043] In some embodiments, the tie layer itself can serve as the
barrier layer. For example, in some embodiments, the multilayer
article comprises a surfactant-treated, hydrophilic, absorbent
layer with a barrier layer directly bonded to the absorbent layer.
In some embodiments, the barrier layer is selected from those
materials identified herein as suitable for use as a tie layer.
[0044] In some embodiments, one or both of the tie layer and the
barrier layer comprise a tackifier. A wide variety of resinous (or
synthetic) materials commonly used in the art to impart or enhance
adhesion of the tie layer to the aliphatic polyester nonwoven
and/or to the polyolefin film core layer may be used as a
tackifier. In some embodiments, the tackifiers have a ring and ball
softening point greater than 90.degree. C. and in some embodiments,
greater than 100.degree. C. according to ASTM E 28 and a weight
average molecular weight of greater than 700 and in some
embodiments, greater than 800 or even greater than 900 g/mol.
[0045] Exemplary tackifiers include rosin, rosin esters of glycerol
or pentaerythritol, hydrogenated rosins, polyterpene resins such as
polymerized beta-pinene, coumaroneindene resins, "C5" and "C9"
polymerized petroleum fractions, and the like. Suitable
commercially available tackifiers include synthetic ester resins,
such as that available under the trade name FORAL (e.g., FORAL 85)
from Hercules Inc., Wilmington, Del., and aliphatic/aromatic
hydrocarbon resins, such as those available under the trade name
ESCOREZ (e.g., ESCOREZ 5690) from Exxon Chemical Co., Houston, Tex.
and REGALREZ (e.g., REGALREZ 6108 and 3102) from Eastman Chemical
Company Kingsport, Tenn.
[0046] Generally, the tackifier is added in amounts required to
achieve the desired tack, adhesion, and/or coefficient of friction
level. This is typically achieved by adding from 1 part to about
100 parts by weight of tackifier per 100 parts by weight of the tie
layer copolymer. In some embodiments, the tackifier is added at
from 2 to 20 parts by weight tackifier to 100 parts by weight of
the tie layer copolymer. The tackifier is selected to provide the
tie layer copolymers with an adequate degree of tack while molten
to promote adhesion and to maintain their adhesion when cooled. As
is known in the art, not all tackifier resins interact with the tie
layer copolymer in the same manner; therefore, some minor amount of
experimentation may be required to select the appropriate tackifier
resin and concentration to achieve the desired adhesive
performance. Such minor experimentation is well within the
capability of one skilled in the adhesive art.
[0047] The present inventors also observed that surfactant in the
surfactant-treated layer can migrate to other layers and to the
external major surfaces of the multilayer article. This migration
was accelerated by winding the material up on itself to form a
jumbo and again when the product was folded upon itself. It was
also discovered that this migration was greatly accelerated by
moisture. Thus, in some embodiments, the multilayer articles are
treated with moisture or high humidity. For example, they may be
exposed to steam in line. In some embodiments, the articles are
sterilized using a method that incorporates high humidity, e.g.
greater than 50% RH, in some embodiments, greater than 65% RH,
greater than 80% RH and even greater than 90% RH. For example, in
some embodiments, the articles are sterilized using ethylene oxide
gas in a humidified chamber. This has been shown to greatly enhance
the absorbency of the sterilized article.
[0048] As an alternative to, or in addition to the use of a tie
layer, the present inventors have also discovered that advantages
can be achieved using a multi-ply (e.g., a dual-ply) absorbent
layer wherein the outermost ply contains sufficient surfactant to
achieve rapid absorbency and the innermost ply, which is bonded to
the barrier layer, contains little to no surfactant. For example,
surprisingly, the present inventors discovered that by providing at
least one inner ply between the surfactant treated outer ply of the
absorbent layer and the barrier layer can greatly improve
adhesion.
[0049] Referring to FIG. 2, multilayer article 200 includes
absorbent layer 210 and barrier layer 230. Absorbent layer 210
includes at least two plies. First ply 213 comprises substantially
less surfactant than second ply 215. In some embodiments, the first
ply is directly bonded to the barrier layer. In some embodiments,
first ply 213 is indirectly bonded for barrier layer 230 using,
e.g., tie layer 220.
[0050] In some embodiments, the first ply comprises at least 50 wt.
% less surfactant, e.g., at least 75 wt. % less surfactant than the
second ply. In some embodiments, the first ply comprises at least
90 wt. %, at least 95 wt. %, or even at least 99 wt. % less
surfactant than the second ply. In some embodiments, the first ply
is substantially surfactant-free, i.e., the first ply comprises no
greater than 0.2 wt. %, in some embodiments, no greater than 0.1
wt. %, no greater than 0.01 wt. %, or even no greater than 0.005
wt. % surfactant based on the total weight of the first ply.
[0051] Such a multi-ply absorbent layer may be produced, for
example, on a multiple beam spunbond or melt blown machine where
one beam has surfactant added and the other beam does not.
Surprisingly, the surfactant does not prevent the aliphatic
polyester fibers from thermally bonding together with themselves in
the high-surfactant content ply or with the non-surfactant treated
fibers of the low-surfactant content ply. Thus, the layered
nonwoven is preferably thermally point bonded. For example, a
heated calendar roll having the desired pattern may be used. In
order to preserve softness and flexibility/hand/drapeability, the
bond pattern is preferably discontinuous and represents less than
30% of the projected area of the major surface. In some
embodiments, the bond pattern is less than 20% of the projected
area.
[0052] In some embodiments, a multi-ply absorbent layer may be
formed by overlaying on a support layer an absorbent nonwoven
fibrous web comprising an overlayer of microfibers on an underlayer
comprising a population of sub-micrometer fibers, such that at
least a portion of the sub-micrometer fibers contact the support
layer. In such embodiments of a multi-ply absorbent layer, it will
be understood that the term "overlayer" is intended to describe an
embodiment wherein at least one ply overlays another ply in a
multi-ply composite web. Furthermore, reference to "a ply" is
intended to mean at least one ply, and therefore each illustrated
embodiment of a multi-ply layer may include one or more additional
plies within the scope of the disclosure.
[0053] In some embodiments, additional layers may be included. For
example, in some embodiments, the exposed surface of the barrier
layer (i.e., the surface opposite the tie layer) may be covered by
an additional layer or coating. For example, in some embodiments,
the texture or feel of the barrier layer may be modified. In some
embodiments, the coefficient of friction of the surface may be
altered, e.g., increased. Referring to FIG. 3, another multilayer
article according to some embodiments of the disclosure is
illustrated. Multilayer article 300 includes absorbent layer 310,
which may include be a single-, or multi-ply layer. Tie-layer 320
is used to indirectly bond absorbent layer 310 to barrier layer
330. Surface layer 340 is disposed on the barrier layer, opposite
the tie layer. In some embodiments, exposed surface 345 of surface
layer 340 may be textured to, e.g., adjust feel and/or coefficient
of friction.
[0054] Generally, any of a wide variety of materials may be used to
form the surface layer. In some embodiments, the surface layer may
have the same composition as the tie layer. In some embodiments,
the surface layer may be coextruded with the barrier and/or tie
layer. In some embodiments, the surface layer may be applied, e.g.,
coated or extruded, in a subsequent step.
[0055] In some embodiments, additional layers may be included. For
example, in some embodiments, a multilayer barrier film may be
used. In some embodiments, multiple surface layers may be
applied.
[0056] Other optional components may be included in one or more
layers of the articles described herein. For example, in some
embodiments, an antimicrobial component may be added to impart
antimicrobial activity to the compositions. The antimicrobial
component is that component of the composition that provides at
least part of the antimicrobial activity, i.e., it has at least
some antimicrobial activity for at least one microorganism. It is
preferably present in a large enough quantity to be leached from
the composition and kill bacteria. It may also be biodegradable
and/or made or derived from renewable resources such as plants or
plant products. Biodegradable antimicrobial components can include
at least one functional linkage such as an ester or amide linkage
that can be hydrolytically or enzymatically degraded.
[0057] Examples of antimicrobial components suitable for use in the
present invention include those described in Applicants' co-pending
application, U.S. Ser. No. 11/609,237, filed on Dec. 11, 2006, and
incorporated by reference herein in its entirety. Certain
antimicrobial components are uncharged and have an alkyl or alkenyl
hydrocarbon chain containing at least 7 carbon atoms. For melt
processing, preferred antimicrobial components have low volatility
and do not decompose under process conditions. The preferred
antimicrobial components contain less than 2 wt. % water, and more
preferably less than 0.10 wt. % (determined by Karl Fischer
analysis). Moisture content is kept low in order to prevent
hydrolysis of the aliphatic polyester and to give clarity to
extruded film. Certain antimicrobial components are amphiphiles and
may be surface active. For example, certain antimicrobial alkyl
monoglycerides are surface active. Certain cationic antimicrobial
amine compounds also may be useful as described in US patent
application 20080142023. For certain embodiments of the invention
that include antimicrobial components, the antimicrobial component
is considered distinct from a surfactant component.
[0058] When used, the antimicrobial component content (as it is
ready to use) is typically at least 1 wt. %, 2 wt. %, 5 wt. %, 10
wt. % and sometimes greater than 15 wt. %. In certain embodiments,
in which a low strength is desired, the antimicrobial component
comprises greater than 20 wt. %, greater than 25 wt. %, or even
greater than 30 wt. % of the composition.
[0059] In some embodiments, one or more of the layers may further
comprise organic and inorganic fillers. In some embodiments,
biodegradable, resorbable, or bioerodible inorganic fillers may be
particularly appealing. These materials may help to control the
degradation rate of the polymer composition. For example, many
calcium salts and phosphate salts may be suitable. Exemplary
biocompatible resorbable fillers include calcium carbonate, calcium
sulfate, calcium phosphate, calcium sodium phosphates, calcium
potassium phosphates, tetracalcium phosphate, .alpha.-tricalcium
phosphate, beta-tricalcium phosphate, calcium phosphate apatite,
octacalcium phosphate, dicalcium phosphate, calcium carbonate,
calcium oxide, calcium hydroxide, calcium sulfate dihydrate,
calcium sulfate hemihydrate, calcium fluoride, calcium citrate,
magnesium oxide, and magnesium hydroxide. A particularly suitable
filler is tribasic calcium phosphate (hydroxy apatite).
[0060] In some embodiments, plasticizers may be used with the
aliphatic polyester thermoplastic and include, for example, glycols
such glycerin; propylene glycol, polyethoxylated phenols, mono or
polysubstituted polyethylene glycols, higher alkyl substituted
N-alkyl pyrrolidones, sulfonamides, triglycerides, citrate esters,
esters of tartaric acid, benzoate esters, polyethylene glycols and
ethylene oxide propylene oxide random and block copolymers having a
molecular weight less than 10,000 daltons preferably less than
about 5000 daltons, more preferably less than about 2500 daltons;
and combinations thereof.
[0061] Other additional components include antioxidant, colorant
such as dyes and/or pigments, antistatic agents, fluorescent
brightening agents, odor control agents, perfumes and fragrances,
active ingredients to promote wound healing or other dermatological
activity, combinations thereof and the like.
[0062] Exemplary multilayer articles according to some embodiments
of the present disclosure were prepared using the materials
summarized in Table 1.
TABLE-US-00001 TABLE 1 Summary of materials used in the examples.
I.D. Description Source (Trade name) PLA-1 Polylactic acid
Natureworks LLC, Blair, Nebraska (INGEO 6202D) PLA-2 Polylactic
acid Natureworks LLC, Blair, Nebraska (INGEO 6751D) DOSS 50%
Docusate Sodium in Polyethylene JLK Industries, Coopersburg,
Pennsylvania Glycol 400 (JDOSS 50P) PP Polypropylene Total
Petrochemical, Brussels, Belgium (TOTAL 3868) LDPE Low density
polyethylene Chevron Phillips Chemical Company LP, The Woodlands,
Texas (MARFLEX 1019) LLDPE Linear low density polyethylene DOW
Chemical Company (DOWLEX 2517) PEG-5 Cocamide Global 7 Industries,
Franklin New Jersey (HETOXAMIDE C4) Tack-1 100% hydrogenated C9
aromatic resin Eastman Chemical, Kingsport, Tennessee (REGALREZ
6108) Tack-2 30% hydrogenated C9 aromatic resin Eastman Chemical
(REGALREZ 3102) Tack-3 50% hydrogenated C9 aromatic resin Eastman
Chemical (REGALITE S5100) Tack-4 50% hydrogenated C9 aromatic resin
Eastman Chemical (REGALITE S5090) Tack-5 70% hydrogenated C9
aromatic resin Eastman Chemical (REGALITE S7125) C12-C15 alkyl
benzoate Innospec Active Chemicals (FINSOLV TN) EMA Ethylene-methyl
acrylate copolymer Dupont, Wilmington, Delaware (ELVALOY AC 12024S)
EAA Ethylene-acrylic acid copolymer DOW Chemical Company with 9.7%
acrylic acid (PRIMACORE 3460) RxGMA-1 HDPE with greater than 1.0
wt. % DOW Chemical Company Performance grafted maleic anhydride
Plastics (AMPLIFY GR 204) RxGMA-2 LDPE with greater than 0.5 wt. %
DOW Chemical Company Performance grafted maleic anhydride Plastics
(AMPLIFY GR 209) RxGMA-3 Plastomer with greater than 0.5 wt. % DOW
Chemical Company Performance grafted maleic anhydride Plastics
(AMPLIFY GR 216) RxCMA-1 Ethylene-maleic anhydride copolymer
Vertellus Health and Specialty Products, (Mw = 60,000) LLC (ZeMac
E60) RxCMA-2 Ethylene-maleic anhydride copolymer Vertellus Health
and Specialty Products, (Mw = 400,000) LLC (ZeMac E400) RxAH-1
Anyhydride modified ethylene-methyl Westlake Chemical Corporation,
acrylate copolymer Houston Texas (TyMax GA7001) RxAH-2 Anyhydride
modified ethylene-methyl Westlake Chemical Corporation acrylate
copolymer (TyMax GA7501) EVA-20 Ethylene vinyl acetate (EVA) DuPont
Company, Willmington, Delaware copolymer with 20% vinyl acetate
(ELVAX 3178Z) (VA) content EVA-25 EVA with 25 wt. % VA content
DuPont Company (ELVAX 350) EVA-28a EVA with 28 wt. % VA content
DuPont Company (ELVAX 3180) EVA-28b EVA with 28 wt. % VA content
Celenase; Edmonton, AB (ATEVA 2821A) EVA-33 EVA with 33 wt. % VA
content Arkema Technical Polymers Division, Colombes Cedex, France
(EVATANE 33-15) EVA-45 EVA with 45% wt VA content Lanxess
Corporation; Pittsburgh, PA (LEVAMELT 456) MA- Maleic
anhydride-modified Dupont Company (FUSABOND C190) EVA1 EVA
copolymer MA- Maleic anhydride-modified Dupont Company (BYNEL E418)
EVA2 EVA copolymer PMMA-PBA-PMMA copolymer Kuraray America
(KURARITY LA2250) Blue MB1 30 pbw blue pigment in 70 pbw PLA Master
batch prepared by 3M Blue MB2 Blue pigment in low density Techmer
Polymer Modifiers, polyethylene Clinton, Tennessee Blue MB3 Blue
pigment in polypropylene Techmer Polymer Modifiers
[0063] Example EX-1 was a multilayer article formed using a
PLA-based, hydrophilic nonwoven absorbent layer. A three-layer
structure comprising a tie-layer, a barrier layer, and an optional
outer layer was extrusion coated using a co-extrusion cast film
process.
[0064] The nonwoven absorbent layer was a single layer made using
one spunbond beam. The nonwoven was produced using PLA that was
treated to increase hydrophilicity by incorporating a melt additive
surfactant package. The resulting composition of the hydrophilic,
nonwoven, absorbent layer was 1.5% by weight PEG-5 Cocamide, 1.5%
by weight DOSS (50% solution); 2% by weight PP; and 93% to 94% by
weight PLA-1. The composition also included 1 to 2% by weight Blue
MB1.
[0065] The multilayer structure was applied to the nonwoven,
absorbent layer using a CLOEREN feedblock, with a B-A-C configured
selector plug, and a drop die, resulting in a three-layer
construction. For consistency, as used herein, the "A" layer refers
to the barrier; the "B" layer refers to the tie layer, and the "C"
layer refers to any optional surface layers. Each layer was fed to
the common feedblock using a separate single screw extruder. As the
melt exited the die lip, it was laid on the nonwoven as it entered
the nip point of a rubber back roll and metal, matte finish, cast
roll. The multilayer structure was applied such that the tie layer
(the B layer) was adjacent to the nonwoven, absorbent layer, and
the C layer was adjacent the cast roll such that it took on the
matte finish.
[0066] As summarized in Table 2, both the tie layer and the outer
layer of the three-layer structure (Layers B and C) consisted of
EMA (24% methyl acrylate content; melt flow index ("MFI") of 20
g/10 min at 190.degree. C.). Barrier layer (Layer A) consisted of a
blend of 37 parts by weight LDPE (MFI of 16 g/10 min at 190.degree.
C., 2.16 kg), 50 parts LLDPE (MFI of 25 g/10 min at 190.degree. C.,
2.16 kg), and 13 parts of Blue MB2. These compositions were coated
with a layer to layer ratio of 1:2:1 (B:A:C).
[0067] Examples EX-2 and EX-3 were prepared in the same manner
except a tackifier was included in Layers A and C, as summarized in
Table 2. The EMA and hydrocarbon resin were pre-compounded at a
weight ratio of 90:10 using a twin screw extruder and pelletizer to
form a master batch. This master batch was then blended 50:50 by
weight with additional EMA. These compositions were coated with a
layer to layer ratio of 2:2:0.1 (B:A:C).
[0068] In Examples EX-1 through EX-3, the processing temperature of
the B-layer was approximately 243.degree. C. and the processing
temperature of the A-layer was about 336.degree. C. The C-Layer for
Examples EX-1 and EX-3 were processed at 236-245.degree. C., while
the C-Layer was processed at about 257.degree. C. for Example
EX-2.
[0069] Adhesion of the barrier layer to the nonwoven layer was
measured according to the procedure specified in the EN Standard
for Textiles--Determination of Resistance to Water
Penetration--Hydrostatic Pressure Test (EN 20811, 1993),
hereinafter referred to as the "Hydrohead Test." Samples were
tested using a pressure increase rate of 6 kPa per minute with the
barrier film side up and no other support.
[0070] The tests were performed shortly after coating, and the
results are reported in Table 2. Failure occurred at the nonwoven,
absorbent layer/tie layer interface. Significant bloating of the
sample occurred as the pressure increased and ultimately resulted
in delamination. The pressure at which an initial small bubble of
film delaminated was recorded as the initial value. The pressure at
which greater than 70% delamination had occurred was recorded as
the failure value.
TABLE-US-00002 TABLE 2 Results for Examples EX-1 to EX-3. Ex. Tie
layer (layer B) Initial (kPa) Failure (kPa) EX-1 100% EMA 3.1 4.5
EX-2 95% EMA + 5% Tack-1 10.2 10.3 EX-3 95% EMA + 5% Tack-2 5.5
6.6
[0071] Most medical fabrics have a need to be sterile. A first set
of samples were selected from EX-2 and sterilized using ethylene
oxide gas (EtO) in a sterilizer available under the trade name
SteriVac 5XL from 3M Company, St. Paul, Minn. The relative humidity
was 56% to 63% during ethylene oxide sterilization at a temperature
of 50.degree. C. for one hour. The sample was then aerated at
45-50.degree. C. for six hours. A second set of samples from EX-2
was sterilized using gamma radiation at a treatment level of about
45 to 48 kGy. The Hydrohead Test was used to measure the failure
values for unsterilized, ethylene oxide sterilized, and gamma
radiation sterilized materials, as reported in Table 3.
TABLE-US-00003 TABLE 3 Effects of sterilization on delamination of
samples of EX-2. Sample Failure (kPa) Unsterilized EX-2 21.7 EtO
Sterilized EX-2 8.6 Gamma Sterilized Ex-2 11.9
[0072] First, comparing the failure pressure of the unsterilized
EX-2 sample in Table 3 (21.7 kPa) to the value recorded in Table 2
(10.3 kPa), there was a significant increase in the bond strength
upon aging of the sample. The results reported in Table 2 were
based on tests conducted shortly after the samples were prepared.
The results reported in Table 3 were obtained using samples that
had aged for approximately three months.
[0073] Second, it appears that sterilization can decrease adhesion.
However, even after sterilization, the failure pressure for sample
EX-2 (with tackifier) was greater than the failure pressure for
unsterilized sample EX-1 (without tackifier).
[0074] Samples were prepared using absorbent layers prepared from
bicomponent fibers. These absorbent layers were prepared as two-ply
structures produced using a two-beam spunbond process. One or both
layers were treated with surfactant to increase hydrophilicity.
[0075] Example 4 included two plies made of a PLA-based web
surfactant-treated to increase the hydrophilicity. Both layers were
prepared fibers made up of approximately 68% by volume of a core
comprising only PLA-1 with about 0.75 to 1.0 wt. % Blue MB1. The
sheath made up about 32% of the fiber volume, and was made of 95
wt. % PLA-1 with 1.5 wt. % PEG-5 Cocamide, 1.5 wt. % DOSS, and 2
wt. % PP.
[0076] Example 5 included two plies made of a PLA-based web, but
only one ply was surfactant-treated to increase hydrophilicity. The
treated, hydrophilic ply was prepared from the core-sheath
bicomponent fibers of Example 4. The untreated ply was prepared
from fibers containing 1.5 wt. % PP blended with PLA-1.
[0077] Example 6 included two plies made of a PLA-based web, but
neither ply was surfactant-treated to increase hydrophilicity. The
core of the fibers contained 98.9 wt. % PLA-1, 1 wt. % PP, and 0.1
wt. % titanium dioxide. The sheath contained 99 wt. % PLA-1 and 1
wt. % PP.
[0078] For each of Examples EX-4 through EX-6, a multi-layer
structure was extrusion coated to apply a tie-layer and barrier
film to the absorbent layer. The total thickness of the multilayer
structure was 23 to 30 microns with an A:B ratio of 3:1. The tie
layer (Layer B) contained 95 wt. % EMA and 5 wt. % Tack-1. The
barrier film (Layer A) was a blend of 42.5 wt. % LDPE, 42.5 wt. %
LLDPE, and 15 wt. % Blue MB2. Examples EX-4 and EX-5 were run with
extrusion temperatures of 234-237.degree. C. for both the A and B
layers. In Example EX-6, the process temperature was 248.degree. C.
for Layer A and 243.degree. C. for Layer B.
[0079] Within thirty minutes of extrusion coating, the samples were
subjected to the Hydrohead Test. For Example EX-4, the tie-layer
was applied to a surfactant-treated ply. For Examples EX-5 and
EX-6, the tie layer was applied to the ply of the absorbent layer
that was not treated. The results are summarized in Table 4.
[0080] Examples EX-4 and EX-5 were sterilized using ethylene oxide
gas at a relative humidity of 56 to 63% and a temperature of
51.degree. C. The samples were aerated at 45 to 50.degree. C. for
six hours and subjected to the Hydrohead Test. These results are
also summarized in Table 4.
[0081] The absorbent capacity of Examples EX-4 through EX-6 was
also measured according to the following Absorbance Test. A ten
centimeter by ten centimeter sample was cut from each example and
weighed to obtain a dry weight. The samples were then floated on
top of fresh deionized water in an immersion tank, with the
non-woven, absorbent layer facing down into the water. No
additional force was applied to submerge the sample. After sixty
seconds, the sample was lifted from the water with a forceps and
held by a corner to drip for five seconds. The sample was then held
by an adjacent corner and allowed to drip for an additional five
seconds. Care was taken not to shake any water from the sample. The
resulting samples were weight to obtain a raw wet weight. Upon
removing the sample, water remained on the balance. The weight of
this water was recorded and subtracted from the raw wet weight to
obtain the true wet weight. Absorbent capacity was calculated as
the ratio of the true wet weight minus the dry weight divided by
the dry weight. The results are reported as a percent in Table
4.
TABLE-US-00004 TABLE 4 Results for multiply absorbent layers.
Failure (kPa) Absorbent I.D. Unsterilized Sterilized capacity EX-4
10.6 6.4 256% EX-5 20.3 14.2 222% EX-6 15.6 Not tested Not
tested
[0082] Corona treatment has been commonly used to improve adhesion
between layers. Two samples of a two-ply, surfactant-treated
absorbent layer were prepared as described in Example EX-4. Both
samples were extrusion coated with a two layer composition. The tie
layer (Layer B) contained 95 wt. % EMA and 5 wt. % Tack-1. The
barrier film consisted of 55 wt. % LDPE, 25 wt. % LLDPE, and 20 wt.
% Blue MB2. The process temperature for both the A and B Layers was
238-243 C. Example EX-7 was prepared without corona treatment. The
absorbent layer of Example 8 was corona treated at 0.3 Joules per
square centimeter just prior to entering the casting station of the
extrusion coater. The Hydrohead Test was performed on samples just
after extrusion coating, and again after ethylene oxide
sterilization. The sterilization was performed at the same
conditions as Example EX-2. The results are summarized in Table 5.
Contrary to expected results, corona treatment led to a decrease in
the adhesion as measured using the Hydrohead Test.
TABLE-US-00005 TABLE 5 Results using corona treated absorbent
layers. Corona Final (kPa) I.D. treated Unsterilized Sterilized
EX-7 No 9.7 6.9 EX-8 Yes 7.7 4.2
[0083] The samples of Example EX-9 were prepared in the same manner
as EX-1, unless otherwise noted. The non-woven absorbent layer of
EX-9 was prepared from a blend of PLAs and included an alternative
surfactant package. The resulting composition of the fibers was
55.3 wt. % PLA-1, 40.0 wt. % PLA-2, 2.6 wt. % DOSS, 1.7 wt. % PP,
and 0.43 wt. % Blue MB3.
[0084] Potential tie layer compositions were evaluated by extrusion
coating only the tie layer onto the absorbent layer. The tie-layer
composition was melted and extruded using a 25 mm twin screw
extruder. The throughput and pressure were controlled using a melt
pump at the end of the extruder. The resulting tie-layer thickness
was 18 to 25 microns. The tie layers were processed at 204.degree.
C., except for Examples EX-9D and 9E, which had low tackifier
concentrations, and were processed at 182.degree. C. The samples
were evaluated using the Hydrohead and Absorbance Tests.
TABLE-US-00006 TABLE 6 Delamination and Absorbent capacity results
for various tie layers. EMA Tackifier Initial Absorbent EX- (wt. %)
Type wt. % (kPa) capacity 9A 100 none 4.6 241% 9B 95 Tack-3 5% 11.0
210% 9C 90 Tack-3 10% 12.6 221% 9D 98.75 Tack-2 1.25% 17.9 Not
tested 9E 97.5 Tack-2 2.5% 18.8 Not tested 9F 95 Tack-2 5% 18.5
166% 9G 90 Tack-2 10% 18.7 184% 9H 95 Tack-1 5% 13.5 212% 9I 90
Tack-1 10% 18.4 204%
[0085] The preceding examples used a tie layer wherein methyl
acrylate was the polar co-monomer. The following examples were
prepared using acrylic acid as the polar co-monomer. These examples
were evaluated in a multi-layer extrusion coating. The layer
configuration was B-A-B at a ratio of 1:2:1. Various tackifiers
were blended with EAA, and coated onto a surfactant treated
hydrophilic PLA-based spunbond similar to the nonwoven used in
previously in Example 9. The results were compared to a sample
using 100% EMA as the tie-layer. The barrier layer consisted of 56
wt. % LDPE and 44 wt. % LLDPE. The sample compositions and initial
delamination values determined using the Hydrohead Test are shown
in Table 7.
TABLE-US-00007 TABLE 7 Delamination results using acrylic acid as
the polar co-monomer. EX. Tie-Layer Initial (kPa) 10A 100% EMA 2.1
10B 100% EAA 3.5 10C 95% EAA + 5% Tack-5 N.T.* 10D 95% EAA + 5%
Tack-3 4.9 10E 95% EAA + 5% Tack-4 4.1 *Not tested. Very poor
adhesion.
[0086] In some embodiments of the present disclosure, the tie layer
may include a polymer including reactive species. The following
examples were prepared by blending EMA with various functional
polymers having maleic anhydride reactive groups either
copolymerized with ("RxCMA") or grafted to ("RxGMA") an
olefin-based polymer. All samples were processed at approximately
204.degree. C. The adhesion was measured using the Hydrohead Test
and the initial delamination values are reported in Table 8. The
results for EX-9A (100% EMA) are repeated here for reference.
TABLE-US-00008 TABLE 8 Initial delamination values based on the
Hydrohead Test. EMA Reactive Polymer Initial EX- (wt. %) Type wt. %
(kPa) 9A 100 none 4.6 11A 90 RxGMA-1 10% 5.6 11B 80 RxGMA-1 20% 3.2
11C 90 RxGMA-2 10% 7.8 11D 80 RxGMA-2 20% 3.2 11E 90 RxGMA-3 10%
10.6 11F 80 RxGMA-3 20% 10.8 11G 99 RxCMA-1 1% 14.4 11H 98 RxCMA-1
2% 11.0 11I 99 RxCMA-2 1% 18.6 11J 98 RxCMA-2 2% 18.8
[0087] Additional examples were prepared using a tackified tie
layer. Reactivity was introduced using an anyhydride-modified
ethylene-methyl acrylate copolymer. In these examples, a two-ply,
surfactant-treated, hydrophilic, PLA-based nonwoven was extrusion
coated with a two layer, construction using two single screw
extruders with single flight screws, a CLOEREN feedblock, and a
drop die. The PLA-based web was made hydrophilic with the addition
of surfactant to the sheath of the fiber in both layers. The sheath
of the fiber made up approximately 32% by volume of the fibers. The
sheath contained 1.5 wt. % PEG-5 Cocamide, 1.5 wt. % DOSS, 2 wt. %
PP, and 95 wt. % PLA-1 (all % wt). The core of the fibers made up
approximately 68% by volume of the fibers and contained only PLA-1
and 0.75 to 1.0 wt. % Blue MB1. The tie layer consisted of the a
pre-compounded blend of 90 wt. % EMA and 10 wt. % Tack-1 to which
varying amounts of reactive polymer were added. The barrier layer
consisted of a blend of LDPE, LLDPE, and blue pigment compounded
into LDPE. The processing temperature for both layers was between
202.degree. C. and 210.degree. C. in all instances. The two-layer
coating had a total thickness of between 18 microns (0.7 mils) and
28 microns (1.1 mils). The layers were coated at approximately a
1:3 ratio of tie layer to barrier film.
[0088] Adhesion was measured using the Hydrohead Test with the
pressure set to increase at a rate of 6 kPa/min over a 100 square
centimeter circle with the barrier film side up. The failure values
for non-sterile and Ethylene Oxide sterilized samples, are
summarized in Table 9.
TABLE-US-00009 TABLE 9 Failure pressure based on the Hydrohead Test
for unsterilized and sterilized samples. (90:10 Reactive
EMA:Tack-1) Polymer Failure (kPa) EX- (wt. %) Type wt. %
Unsterilized Sterilized REF. 50 EMA* 50% 11.3 6.7 11A 90 RxAH-1 10%
11.4 11.0 11B 80 RxAH-1 20% 10.6 7.9 11C 70 RxAH-1 30% 11.0 8.9 11D
90 RxAH-2 10% 12.1 8.8 11E 80 RxAH-2 20% 12.7 6.2 11F 70 RxAH-2 30%
9.3 4.6 *EMA is not a reactive polymer. Included for reference
purposes.
[0089] Various ethylene-vinyl acetate copolymers (EVA) were
evaluated as potential tie-layers for bonding a surfactant-treated,
hydrophilic, PLA-based spunbond web to an adjacent
polyethylene-based barrier layer. These samples were evaluated
qualitatively on a pass/fail basis for adhesion and "hand" of the
fabric.
[0090] A hydrophilic, PLA-based, spunbond web similar to that
referenced in Example 9 was extrusion coated with a 3-layer
structure. The EVA-based tie-layer (Layer-B) was adjacent the
spunbond PLA web. The barrier layer (Layer A) was positioned
between the tie-layer and a surface layer (Layer C). The barrier
layer (Layer A) consisted of a blend of 44.5 wt. % LDPE, 44.5 wt. %
LLDPE, and 11.0 wt. % Blue MB2 and provided the bulk of the
three-layer structure. The surface layer (Layer C) consisted of a
blend of 44.5 wt. % LDPE, a 44.5 wt. % polyolefin plastomer
(AFFINITY EG8185 available from Dow Chemical Company), and 11.0 wt.
% Blue MB2. Layer C provided the exposed surface of the multi-layer
article with a desirable coefficient of friction. The layers were
coated at a 1:5:1 ratio B:A:C.
[0091] Samples prepared with EVA having a vinyl acetate content of
20 wt. % (EVA-20), 25 wt. % (EVA-25) and 28 wt. % (EVA-28a and 28b)
showed poor adhesion. Acceptable adhesion was obtained when the
vinyl acetate content was increased to 33 wt. % (EVA-33).
[0092] An EVA copolymer with 45% wt vinyl acetate content (EVA-45)
was also evaluated using the same procedure. In this example, the
PLA-based web was made hydrophilic with the addition of surfactant
to the sheath of the fiber in both layers. The sheath of the fiber
made up approximately 32% by volume of the fibers. The sheath
contained 1.5% PEG-5 Cocamide, 1.5 wt. % DOSS, 2 wt. % PP, and 95
wt. % PLA-1. The core of the fibers made up approximately 68% by
volume of the fibers and contained only PLA-1 and a blend
containing blue pigment.
[0093] Adhesion for the EVA-45 based tie layer was measured using
the Hydrohead Test. The initial delamination commenced at an
average value of 15.1 kPa, with failure at 16.1 kPa. This polymer
with a high level of polar vinyl acetate monomer (45%) bonded much
better than those polymers with lower VA content, particularly
those having a vinyl acetate content of less than 30 percent by
weight.
[0094] Tie layers were prepared by combining various amounts of a
C12-C15 alkyl benzoate plasticizer to an ethylene-methyl acrylate
copolymer (EMA). In these examples, a two-ply, surfactant-treated,
hydrophilic, PLA-based nonwoven was extrusion coated with a two
layer, construction using two single screw extruders with single
flight screws, a CLOEREN feedblock, and a drop die. The PLA-based
web was made hydrophilic with the addition of surfactant to the
sheath of the fiber in both layers. The sheath of the fiber made up
approximately 32% by volume of the fibers. The sheath contained 1.5
wt. % PEG-5 Cocamide, 1.5 wt. % DOSS, 2 wt. % PP, and 95 wt. %
PLA-1 (all % wt). The core of the fibers made up approximately 68%
by volume of the fibers and contained only PLA-1 and 0.75 to 1.0
wt. % Blue MB1. The barrier layer consisted of a blend of LDPE,
LLDPE, and blue pigment compounded into LDPE. The processing
temperature for both layers was between 202.degree. C. and
210.degree. C. in all instances. The two-layer coating had a total
thickness of between 18 microns (0.7 mils) and 28 microns (1.1
mils). The layers were coated at approximately a 1:3 ratio of tie
layer to barrier film. The Hydrohead Test was performed before and
after sterilization. The results are summarized in Table 10.
TABLE-US-00010 TABLE 10 Effects of plasticizer in the tie layer on
the failure pressure based on the Hydrohead Test. Plasticizer
Failure (kPa) EX- wt. % Unsterilized Sterilized REF. 0% 40 .+-. 11
2 .+-. 1 12A 10% 26 .+-. 4 1.4 .+-. 0.4 12B 20% 20 .+-. 1 1.2 .+-.
0.3 12C 20% 21 .+-. 2 1.2 .+-. 0.2
[0095] In some embodiments, tie layer performance can be improved
by blending additional polymers in to the composition. For
examples, the present inventors discovered that the inclusion of a
thermoplastic elastomer can result in improved adhesion. Suitable
thermoplastic elastomers include diblock and triblock copolymers.
Exemplary block copolymers include those based on alkyl acrylate
and alkyl methacrylate block. In some embodiments, the alkyl
methacrylate is methyl methacrylate. In some embodiments, the alkyl
acraylte is butyl acraylate. In some embodiments, the thermoplastic
elastomer is a polymethacrylate-polyacrylate-polymethacrylate
triblock copolymer, e.g., poly(methyl methacrylate)-poly(butyl
acrylate)-poly(methyl methacrylate) copolymer. Suitable
thermoplastic elastomers include those available from Kurary
America under the trade name KURARITY.
[0096] Tie layers were prepared by blending a PMMA-PBA-PMMA block
copolymer with an ethylene-methyl acrylate copolymer (EMA).
Additional tie layers were prepared by adding plasticizer to the
block copolymer/EMA blends. The nonwoven multilayer articles were
prepared as described for Examples 12A-C. The Hydrohead Test was
performed before and after sterilization. The results are
summarized in Table 11.
TABLE-US-00011 TABLE 11 Failure pressure based on the Hydrohead
Test. PMMA- EMA PBA-PMMA Plasticizer Failure (kPa) EX- wt. % wt. %
wt. % Unsterilized Sterilized REF. 100% 0% 0% 36 .+-. 6 2.0 .+-.
0.3 13A 75% 25% 0% 70 .+-. 10 14 .+-. 1 13B 25% 75% 0% 230 .+-. 20
200 .+-. 25 13C 67.5 22.5% 10% 51 .+-. 7 17 .+-. 2 13D 67.5 22.5%
10% 40 .+-. 4 10 .+-. 2 13E 22.5 67.5% 10% 21 .+-. 4 7 .+-. 3 13F
22.5 67.5% 10% 28 .+-. 8 7 .+-. 4 13G 60% 20% 20% 24 .+-. 4 9 .+-.
1
[0097] The multi-layer articles of the present disclosure may be
used in a wide variety of application. In some embodiments, these
articles may be used in medical applications, including those
requiring sterilization. Exemplary articles include drapes, gowns,
warming blankets, and the like.
[0098] Various modifications and alterations of this invention will
become apparent to those skilled in the art without departing from
the scope and spirit of this invention.
* * * * *